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Mavrix welding automation processes

Mavrix welding automation processes

Mavrix manufactures machines that can use most common welding processes.  In some cases we can use the same torch to weld FCAW, SAW and GMAW with small front end changes on the torch.  Review processes for more information.


Nearly all of the portable equipment manufacture by Mavrix uses Flux-cored arc welding (FCAW or FCA).  FCAW requires a continuously-fed 

consumable tubular wire containing flux.  The consumable is typically supplied on 60# coils or in tubs or drums of various size.  The process is done with constant-voltage.  The flux itself is relied upon to generate the necessary protection from the atmosphere, producing both gaseous protection and liquid slag protecting the weld. The process is widely used in hard facing and metal build up because of its high welding speed and portability.


Many flux cored wires contain more than just flux, it also contains various ingredients that when exposed to the high temperatures of welding generate a shielding gas for protecting the arc. This type of FCAW is attractive because it is portable and generally has good penetration into the base metal. Also, windy conditions need not be considered. Some disadvantages are that this process can produce excessive, noxious smoke and appropriate operator protective must be considered.


Submerged arc welding (SAW) is a common process that can be added to any of Mavrix fixed automation product. The molten weld and the arc zone are protected from atmospheric contamination by being "submerged" under a blanket of granular fusible flux consisting of lime, silica, manganese oxide, calcium fluoride, and other compounds. When molten, the flux becomes conductive, and provides a current path between the electrode and the work. This thick layer of flux completely covers the molten metal thus preventing spatter and sparks as well as suppressing the intense ultraviolet radiation and fumes that are a part of the shielded metal arc welding (SMAW) process.  


Gas metal arc welding (GMAW), sometimes referred to by its subtypes metal inert gas (MIG) welding or metal active gas (MAG) welding, is a welding process in which an electric arc forms between a consumable wire electrode and the workpiece metal(s), which heats the workpiece metal(s), causing them to melt, join or create a buildup layer or hardfacing layer.

Along with the wire electrode, a shielding gas feeds through the welding gun, which shields the process from contaminants in the air.  A constant voltage, direct current power source is used with all Mavrix GMAW welding systems.  


The process of ID bore welding is most often complicated simply by the diameter and reach inside the part.  Mavrix can manufacture automation that uses FCAW or GMAW in various bore size and reach.  We have designed and implemented a FCAW welding lance that is 11 feet long and used to hard face 3” ID pipe.


Mavrix has implemented PTA on a variety of machine platforms.  The customer is able to select what PTA equipment is used and the machine control is then integrated to work with the arc starting in the PTA process.  Plasma transferred arc (PTA) hardfacing is a versatile method of depositing high-quality metallurgically fused deposits on relatively low cost surfaces. Soft alloys, medium and high hardness materials, and carbide composites can be deposited on a variety of substrates to achieve diverse properties such as mechanical strength, wear and corrosion resistance. 


Arc Spray is the most productive and economical of all thermal spray coating systems. Arc Spray uses DC power to energize two conductive wires: one positive and the other negative. These energized wires are then fed through a feeder into a gun head. It is at the gun head that the wires meet and arc against each other, thus creating molten material. Ordinary dry compressed air is introduced into to the arc zone, atomizing the molten material into tiny droplets while also propelling then toward the prepared part. As the droplets hit the work piece or part, they flatten out and make splats. The splats interlock one on top another to create an extremely strong mechanical bond.


Submerged Arc Strip Cladding utilizes an arc that runs back and forth at high speed along the strip, depositing weld metal onto the base material. Because this is an arc process there will be penetration into the base material resulting in dilution levels of ~ 20%. Deposition rates are in the region of 

10/12kg/hr for 60mm strip and are restricted by how much current can be applied. Care must


Electro Slag Strip Cladding (ESW) utilizes a conductive flux and the resulting Joule heating effect to melt the strip into the liquid slag; which is transferred into molten metal deposited onto the base material. The ESW process has significant advantages over its SAW counterpart.  As there is no arc present, there is limited dilution into the base material, typically 10% (compared with 20% SAW for 60x0.5mm strip). This can be further enhanced by tailoring flux type and deposition technique .Leading to the ability to deposit single layer full chemistry with over alloyed strip. Higher current levels can be used giving deposition rates of 22-25kg/hr. for 60mm strip. (SAW 10/12kg/hr.) 




    The equipment herein has been designed for hardfacing or metal build up.  Mavrix highly recommends that the end user of this equipment review OSHA 29 CFR 1910.1026 and ensure that they are in compliance with this standard when operating this equipment.  The end user must specifically implement available engineering controls to comply with the permissible exposure limits set forth by this standard.  A brief summary of the standard follows...  



    On February 28, 2006, OSHA promulgated a revised hexavalent chromium standard for general industry ("the Standard") that includes a permissible exposure limit ("PEL") for hexavalent chromium of 5 micrograms per cubic meter ("µg/m3") measured as an 8-hour time-weighted average ("TWA"), and a deadline of May 31, 2010, for employers to come into compliance with this PEL through the implementation of engineering controls. The deadline for compliance with the remaining provisions of the Standard, including those requiring the use of respiratory protection to comply with the PEL, is November 27, 2006, for employers with twenty (20) or more employees, and May 30, 2007, for employers with nineteen (19) or fewer employees. 29 CFR 1910.1026, 71 FR 10100 (Feb. 28, 2006);

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